Blister packaging and methods of forming the same

ABSTRACT

A method of forming a blister package with product in one method includes providing a blister card. An interior portion of the blister card is removed so as to form an opening. A blister pack is inserted into the opening. The blister pack includes a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls. The blister pack forms at least one undercut in an interior thereof. The product is placed into the interior of the blister pack. A plug is placed into the at least one undercut of the blister pack so as to close the interior of the blister pack. The plug is of the same size and shape as the interior portion of the blister card.

CLAIM OF PRIORITY AND CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. Provisional Patent Application No. 62/054,760, which was filed on Sep. 24, 2014, and is incorporated herein by reference in its entirety and for all purposes.

FIELD OF THE INVENTION

The present invention relates generally to packaging that holds and displays products. More specifically, the present invention relates to a blister packaging and methods of forming the same that is more efficient.

BACKGROUND

Blister packaging has been used to provide packaging for many years. Blister packaging captures the product between two layers of bonded material. One type of blister packaging is a clamshell. Clamshell packaging is a hinged system that traps a paperboard card between two thermoformed plastic layers and is sealed. The existing blister packaging processes tend to be complicated and inefficient. It would be desirable to have a blister package and method of the same that addresses these shortcomings.

SUMMARY

According to one method, a blister package is formed with product and includes providing a blister card. An interior portion of the blister card is removed so as to form an opening. A blister pack is inserted into the opening. The blister pack includes a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls. The blister pack forms at least one undercut in an interior thereof. The product is placed into the interior of the blister pack. A plug is placed into the at least one undercut of the blister pack so as to close the interior of the blister pack. The plug is of the same size and shape as the interior portion of the blister card.

According to another method, a blister package is formed with product and includes providing a blister card with an opening. A blister pack is inserted into the opening. The blister pack includes a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls. The blister pack forms at least one undercut in an interior thereof. The product is placed into the interior of the blister pack. The plug is placed into the at least one undercut of the blister pack so as to close the interior of the blister pack. The plug is of the same size and shape as the opening of the blister card.

According to a further method, a blister package is formed with product and includes providing a blister card. The blister card comprises corrugated paperboard. An interior portion of the blister card is removed so as to form an opening. A blister pack is inserted into the opening. The blister pack includes a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls. The plurality of walls assists in forming the at least one undercut. The blister pack includes polymeric material. The product is placed into the interior of the blister pack. The interior portion of the blister card is placed into the at least one undercut of the blister pack to form a plug to close the interior of the blister pack. The blister package is formed in the absence of adhesive, tape or fasteners.

According to one embodiment, a blister package comprises a blister card with an opening formed therein, a blister pack, product and a plug. The blister pack is inserted through the opening. The blister pack includes a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls. The blister pack forms at least one undercut in an interior thereof. The product is located into the interior of the blister pack. The plug is placed into the at least one undercut of the blister pack so as to close the interior of the blister pack. The plug is of the same size and shape as the opening of the blister card.

The above summary is not intended to represent each embodiment or every aspect of the present invention. Additional features and benefits of the present invention are apparent from the detailed description and figures set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 is an exploded view of a blister package according to one embodiment.

FIG. 2A is a front perspective view of a blister package with a product therein according to one embodiment.

FIG. 2B is a back perspective view of the blister package of FIG. 2A.

FIG. 3A is an enlarged perspective view of a blister pack used in the blister package of FIGS. 2 a and 2 b.

FIG. 3B is an enlarged partial side view of the blister pack of FIG. 3A.

FIG. 4 is an exploded view of a blister package according to another embodiment.

While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

FIG. 1 illustrates a blister package 10 according to aspects of the present disclosure. FIG. 1 is shown without product to better illustrate the components of the blister package. Each of the blister packages of the present invention includes product. The blister package 10 of FIG. 1 includes a blister card 12, a blister pack 14 and a plug 16. The blister card 12 includes an opening or recess 30 formed therein. The opening 30 of FIG. 1 includes a plurality of indentations 32 a-d that generally correspond in shape to an exterior contour of the blister pack 14 to assist in forming a generally tight fit between the blister pack 14 and the blister card 12. It is contemplated that more or less of the indentations may be formed in the opening than depicted in FIG. 1. For example, two indentations may be used to form a generally tight fit between the blister pack 14 and the blister card 12. It is also contemplated that no indentations may be used in forming the opening in the blister card.

The blister card 12 is shown in FIG. 1 as a generally rectangular shape. It is contemplated that the blister card may be of different shapes and sizes than that depicted in FIG. 1. The blister card on a front surface (not shown in FIG. 1) will typically include printed information about the contained product therein.

The blister pack 14 is inserted through the opening 30 formed in the blister card 12. The blister pack 14 includes a front surface 40, a plurality of walls 42 a-42 d extending continuously from the front surface 40, and a flange 44 extending outwardly from the plurality of walls 42 a-42 d. The flange 44 is shown as extending continuously from the plurality of walls 42 a-42 d. It is contemplated that the at least one flange may be a plurality of flanges extending from the plurality of walls (i.e., not continuous).

To assist in securing or locking the blister pack 14 into the blister card 12, an exterior surface of the plurality of walls 42 a-42 d includes at least one undercut 60. A more detailed view of at least one undercut is shown in FIG. 3B (undercut 160 in blister pack 114). The at least one undercut is typically formed in a number of selected areas around the exterior surface of the plurality of walls. Thus, the blister package typically contains a plurality of undercuts on the exterior surface of the plurality of walls. The at least one undercut may be exactly one undercut that extends around the entire exterior surface of the plurality of walls.

The blister pack 14 of FIG. 1 is shown as being a generally rectangularly-shaped tray. The size and shape of the blister pack 14 corresponds with the size and shape of the opening 30 such that the blister pack 14 can be inserted into and locked with the blister card 12.

Referring still to FIG. 1, the plurality of walls 42 a-42 d extends continuously from the front surface 40. The plurality of walls 42 a-42 d extends upwardly (as viewed in FIG. 1) from the front surface. The plurality of walls may also extend generally outwardly from the front surface. It is contemplated that the plurality of walls may extend in a generally perpendicular manner from the front surface or may even extend generally inwardly from the front surface.

To assist in frictionally locking or securing the plug 16, the blister pack 14 of FIG. 1 forms at least one undercut 46 in an interior thereof. A more detailed view of at least one undercut is shown in FIG. 3A (undercuts 146 a-c in the blister pack 114). The at least one undercut is typically formed in a number of selected areas around the interior surface of the plurality of walls. Thus, the blister package typically contains a plurality of undercuts. The at least one undercut may be exactly one undercut that extends around the entire interior surface of the plurality of walls. In one embodiment, the plurality of walls forms at least one stop that prevents or inhibits the plug from further extending into an interior of the blister pack.

For example, in FIG. 3A, the blister pack 114 includes a plurality of walls 142 a-c that form respective stops 150 a-c. Each of the stops 150 a-c has a generally flat surface. It is contemplated that the stops may be of different sizes and shapes. The at least one stop assists in maintaining the frictional lock between the plug and the blister pack by preventing or inhibiting the plug from extending too far into the interior of the blister pack. The blister pack 14 also further includes a plurality of indentations 48 a-c (shown in FIG. 1) that assists in engaging the plug and the blister pack 14 by forming a generally tight fit.

The front surface 40 of FIG. 14 is shown as being general flat and smooth in FIG. 1. The front surface of the blister pack, however, does not have to be generally flat and smooth such as shown in, for example, FIGS. 3A and 3B. The blister pack 114 of FIG. 3A has two portions 140 a, 140 b extending outwardly to accommodate product such as, for example, light bulbs. Thus, the front surface of the blister pack is desirably shaped and sized to efficiently contain the desired product.

The blister pack is typically transparent or translucent so as to allow the customer to see the product contained therein. The blister pack typically comprises a polymeric material. Some non-limiting examples of polymeric materials that may be used to form the blister pack include polyvinyl chloride (PVC), polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), cyclic olefin copolymers (COCs), and combinations thereof. It is contemplated that the blister pack may be made of different materials than polymeric materials. Although less desirable, the blister pack may be made of materials that will not allow a customer to see the product contained therein.

The blister pack may be formed by methods such as thermoforming or injection molding.

The plug 16 is shown as being generally flat and generally rectangular. The plug 16 frictionally locks with the undercut 46 formed in the blister pack 14. Once the plug 16 engages the undercut 46, any product contained within the blister pack is securely located therein. The plug 16 also functions to prevent or inhibit the blister pack 14 from flexing, which assists in maintaining the positioning of the blister pack 14. In FIG. 1, the plug 16 is the same size and shape as the opening 30. The material removed in forming the opening desirably may be used as the plug in one embodiment.

Referring to FIG. 2B, a back view of a blister package 110 is shown. The blister package 110 of FIGS. 2A, 2B includes a blister card 112, a blister pack 114, a plug 116 (only shown in FIG. 2B) and product 160 (only shown in FIG. 2A). Referring back to FIG. 2B, a flange 144 of the blister pack 114 is shown in relationship to the blister card 112 and the plug 116. The plug 116 forms a friction lock with the blister pack 114 in a similar manner as described above with respect to the plug 16 and the blister pack 14.

The blister packages 10, 110 of FIGS. 1, 2A, 2B are formed in the absence of adhesive, tape or fasteners (e.g., clips, staples, etc.). Thus, the only components for forming the blister packages 10, 110 besides the product are shown in FIGS. 1, 2A, 2B—the blister card 12, 112, the blister pack 14, 114 and the plug 16, 116.

It is contemplated that in another embodiment, adhesive, tape or fasteners may be used in the blister package. For example, an adhesive, tape or fastener may be used to attach a flange of a blister pack to a blister card if more security is desired between the blister card and the blister pack. In such an embodiment, additional support may be obtained, while making it more difficult to remove the product from the blister package. In this embodiment using adhesive, tape or fastener, the plug would remain frictionally locked to the blister pack and would not include any adhesive, tape or fastener.

The product is captured between the blister pack and the plug. The blister packaging can contain any number of distinct and varying products. Non-limiting examples of product include light bulbs, batteries, lip balm, bandages, ear plugs, lotions, hand creams and air fresheners. In one non-limiting example, the blister packaging 110 of FIG. 2A includes the product 160, which are light bulbs.

According to one method, a blister package is formed by providing a blister card. An interior portion of the blister card is removed so as to form an opening. A blister pack is inserted into the opening of the blister card. Product is placed into an interior of the blister pack. In one process, the product is placed into the blister pack before the blister pack is inserted into the opening of the blister card. In another process, the product is placed into the blister pack after the blister pack is inserted into the opening of the blister card. The blister pack includes a front surface, a plurality of walls extending continuously from the front surface and at least one flange extending outwardly from the plurality of walls. The blister pack forms at least one undercut in an interior thereof. A plug is placed into the at least one undercut of the blister pack so as to close the interior of the blister pack. The plug is of the same size and shape of the interior portion as the blister card.

The blister card and the plug are typically formed from the same material. In one process, the interior portion of the blister card is the plug. This process is desirable because of the efficiency of using the interior portion from the blister card in forming the plug.

The present invention is advantageous in reducing costs by limiting or eliminating sealing equipment and tooling usage, reducing assembly time and material usage, shortening the overall transit cycle, lowering energy and reducing waste (if the plug is formed from the interior portion of the blister card). The blister packaging is also easier for the customer to open as compared to existing blister packaging.

According to another method, a blister package is formed with product and includes providing a blister card with an opening. A blister pack is inserted into the opening. The blister pack includes a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls. The blister pack forms at least one undercut in an interior thereof. The product is placed into the interior of the blister pack. The plug is placed into the at least one undercut of the blister pack so as to close the interior of the blister pack. The plug is of the same size and shape as the interior portion of the blister card.

FIG. 1 depicts the direction for assembling the blister card 12, the blister pack 14 and the plug 16 via arrows A1 and A2. During this assembly process, product (not shown in FIG. 1) would be added at some point before the plug 16 frictionally locks with the blister pack 14.

The opening or recess of the blister card may be formed by die cutting. A product assembler uses a respective one of a plurality of blister cards, a plurality of blister packs and plurality of plugs with product to form the blister packaging. Since each of the blister cards and the plugs are the same, the plug to be used does not have to come from the exact blister card, but just one of the blister cards.

To assist in forming the opening in a blister card, nicks, perforations, lines of weaknesses, cut lines, scores or any combination thereof may be formed on the blister card to partially form an opening. These blister cards would typically be shipped to an assembler. During the assembly process, an operation such as punching would be performed to fully form the opening. A product assembler uses a respective one of a plurality of blister cards, a plurality of blister packs and plurality of plugs with the product to form the blister packaging as described above.

The blister cards and plugs described herein are typically manufactured using paperboard, corrugated paperboard or cardboard. It is to be understood that the principles of this invention could be applied to blister cards and plugs made of other materials, such as corrugated fiberboard, non-corrugated fiberboard, solid-fiber board, polymeric materials, and other materials.

In one embodiment, the blister package uses a blister card including paperboard, a plug including paperboard and a blister pack including polymeric materials. In another embodiment, the blister package uses a blister card including corrugated paperboard, a plug including corrugated paperboard and a blister pack including polymeric materials.

The thicknesses of the material to be used as the blister card and plugs are typically from 1/32 to ½ inch and, more specifically, from 1/16 to 5/32 of an inch.

In another embodiment, a slotted die cut may be used instead of the at least one undercut. The at least one slotted die cut secures a blister pack and a blister card. One non-limiting example of a blister package using at least one slotted die cut is depicted in FIG. 4. FIG. 4 depicts an exploded view of a blister package 210. The blister package 210 includes a blister card 212, a blister pack 214 and a plug 216. It is noted that blister package 210 does not include product to better view the components forming the blister package 210. The blister package 210 (including the blister card 212, the blister pack 214 and the plug 216) functions in a similar manner as respective blister package 10 (including the blister card 12, the blister pack 14 and the plug 16) or blister package 110 except for the locking mechanism.

The blister card 212 includes an opening or recess 230. The blister card 212 includes a plurality of extensions 228 a-d extending into the recess 230. The blister pack 214 includes a plurality of walls 242 a-d in which each of the plurality of walls 242 a-d forms a respective one of a plurality of slots 226 a-d. The size and shape of the extensions 228 a-d generally corresponds with the size and shape of the plurality of slots 226 a-d such the extensions 228 a-d extend through a respective one of the slots 226 a-d. The extensions 228 a-d and slots 226 a-d assist in securing or locking the blister pack 214 and the blister card 212. It is also contemplated that the number of slots and extensions may vary from than depicted in FIG. 4.

It is contemplated that a blister card may include a combination of extensions and slots that would correspond with a blister pack including a combination of extensions and slots.

In another embodiment, a carton may be used instead of a blister card. More specifically, a carton may be formed with an opening or recess. In this embodiment, the carton would be used with the above described blister packs and the plugs to form a package.

While the present invention has been described with reference to one or more particular embodiments, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. Each of these embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. 

What is claimed is:
 1. A method of forming a blister package with product, the method comprising the acts of: providing a blister card; removing an interior portion of the blister card so as to form an opening; inserting a blister pack into the opening, the blister pack including a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls, the blister pack forming at least one undercut in an interior thereof; placing the product into the interior of the blister pack; and placing a plug into the at least one undercut of the blister pack so as to close the interior of the blister pack, the plug being of the same size and shape as the interior portion of the blister card.
 2. The method of claim 1, wherein the removing of the interior portion is performed by die cutting.
 3. The method of claim 1, wherein the removing of the interior portion is assisted by nicks, perforations, lines of weaknesses, cut lines, scores or any combination thereof.
 4. The method of claim 3, wherein the removing of the interior portion is performed by punching.
 5. The method of claim 1, wherein the product is placed into the interior of blister pack after the blister pack is inserted into the opening.
 6. The method of claim 1, wherein the blister package is formed in the absence of adhesive, tape or fasteners.
 7. The method of claim 1, wherein the interior portion includes at least one indentation.
 8. The method of claim 1, wherein the at least one flange is exactly one flange that extends continuously from the plurality of walls.
 9. The method of claim 1, wherein the interior portion of the blister card is the plug.
 10. The method of claim 1, wherein the plurality of walls further forms a stop, the stop inhibiting or preventing the plug from further extending into the interior of the blister pack.
 11. The method of claim 1, wherein the blister card and the plug comprises paperboard and the blister pack comprising polymeric material.
 12. The method of claim 11, wherein the blister card and the plug comprises corrugated paperboard and the blister pack comprising polymeric material.
 13. A method of forming a blister package with product, the method comprising the acts of: providing a blister card with an opening; inserting a blister pack into the opening, the blister pack including a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls, the blister pack forming at least one undercut in an interior thereof; placing the product into the interior of the blister pack; and placing a plug into the at least one undercut of the blister pack so as to close the interior of the blister pack, the plug being of the same size and shape as the opening of the blister card.
 14. The method of claim 13, wherein the blister package is formed in the absence of adhesive, tape or fasteners.
 15. The method of claim 13, wherein the plurality of walls further forms a stop, the stop inhibiting or preventing the plug from further extending into an interior of the blister pack.
 16. The method of claim 13, wherein the blister card and the plug comprises paperboard and the blister pack comprising polymeric material.
 17. A method of forming a blister package with product, the method comprising the acts of: providing a blister card, the blister card comprising corrugated paperboard; removing an interior portion of the blister card so as to form an opening; inserting a blister pack into the opening, the blister pack including a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls, the plurality of walls assisting in forming the at least one undercut, the blister pack including polymeric material; placing the product into the interior of the blister pack; and placing the interior portion of the blister card into the at least one undercut of the blister pack to form a plug to close the interior of the blister pack, wherein the blister package is formed in the absence of adhesive, tape or fasteners.
 18. A blister package containing product, the blister package comprising: a blister card with an opening forming therein; a blister pack inserted through the opening, the blister pack including a front surface, a plurality of walls extending continuously from the front surface, and at least one flange extending outwardly from the plurality of walls, the blister pack forming at least one undercut in an interior thereof; the product being located into the interior of the blister pack; and a plug placed into the at least one undercut of the blister pack so as to close the interior of the blister pack, the plug being of the same size and shape as the opening of the blister card.
 19. The blister package of claim 18, wherein the blister package is formed in the absence of adhesive, tape or fasteners.
 20. The blister package of claim 18, wherein the blister card and the plug comprises paperboard and the blister pack comprising polymeric material. 